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By Sabine Verryn, Johan de Villiers

"Through the application of the Rietveld method, X-ray diffraction analysis has developed into a fully quantitative method for phase analysis. The Rietveld method itself has progressed from an unstable method that required constant operator intervention to a stable and robust method suited even for routine analysis. The method however, requires a good initial calibration and periodic checks on its precision and accuracy.Several examples from minerals processing, pyrometallurgy, and materials science show the strengths and applicability of the method. The limitations and sources of error are also discussed.1. IntroductionDiffraction of X-rays by matter has been used for more than 80 years, initially to elucidate the structure of crystalline matter, and to investigate the bonding between atoms. The first development of powder diffraction cameras and the later development of X-ray diffractometers saw the development of methods to identify phases and to try to quantify them in mixtures. A comprehensive database and search-match techniques have been developed over the ensuing years. Effective and accurate quantification had to wait for the so-called Rietveld' analysis where the total diffraction pattern is used and where the crystal structure data for the constituent phases are needed as input. Overlapping of diffraction peaks of different phases is handled without difficulty and reliable results can be obtained in spite of this occurrence.The development of methods for structure analysis from powder data has also progressed rapidly and more and more complex structures are being solved from first principles, i.e. without knowledge of unit cell or space group data. Because of the ease of use of the Rietveld method, it is finding increased application in metallurgy, especially in the quantification of phases of importance in minerals processing, in pyrometallurgical processes, and in materials characterization. This study will examine the principles of the Rietveld method, its application in metallurgy, and finally also the common pitfalls that need to be avoided.2. Rietve1d AnalysisAs the Rietveld method compares the experimental diffraction pattern with one calculated from known crystal structure data, the following data are needed:•,An XRD Pattern with as Iowa background as possible. This should have good resolution and high diffraction peak intensities. With modem X-ray detectors, this can be achieved in minutes rather than hours.•,Instrumental parameters such as goniometer radii and slit sizes are needed. These are the so-called ""Fundamental parameters"". They are used to calculate the shapes of the resultant diffraction peak profiles that are caused by the instrument. The parameters are used to correctly separate the instrumental effects on the diffraction pattern from the sample effects."

Jan 1, 2014

By M. Bester, R. Carey, T. Russell, J. van Heerden

"In order to reach the goal of optimal and safe extraction of the mineral reserve, the mining industry is increasingly focusing on reconciliation across the mining value chain to ensure that the mining process occurs in a progressively more predictable manner. This will consequently improve the understanding of mine plans and their associated implementation risks, ultimately leading to increased investor confidence. In terms of geotechnical engineering, mine to design performance assessment is a critical aspect of mine to plan adherence focusing on the complex aspects influencing slope performance. A mine to design reconciliation process therefore needs to systematically track implementation and geotechnical aspects in order to review or update slope design criteria and pit layouts according to the mine planning cycle as the mine is developed. This paper describes the development and implementation of a standardized mine to design reconciliation system for operations utilizing laser scanning technology, analysis tools, as well as associated key performance indicators. Performance is evaluated on final pit boundaries in terms of geometry achieved as well as blast performance evaluation of face conditions. These aspects as well as the resulting catch berm capacity should be captured in an information system, enabling longer term trend analysis and detailed root cause analysis where unsatisfactory outcomes occur. Adverse outcomes should subsequently be incorporated into the mine’s risk management process informing risk mitigation measures including blast design adjustments, slope design changes, or rockfall protection measures. IntroductionIn order to reach the goal of optimal and safe extraction of the mineral reserve, the mining industry is increasingly focusing on reconciliation across the mining value chain to ensure that the mining process occurs in a progressively more predictable manner. This will consequently improve the understanding of mine plans and their associated implementation risks, ultimately leading to increased investor confidence. In terms of geotechnical engineering, mine to design performance assessment is a critical aspect of mine to plan adherence focusing on the complex aspects influencing slope performance. A mine to design reconciliation process therefore needs to systematically track implementation and geotechnical aspects in order to review or update slope design criteria and pit layouts according to the mine planning cycle as the mine is developed."

Jan 1, 2016

By J. Labuschagne

The primary factor contributing to the profitability of a platinum mine and its associated concentrator is the time taken from the first hoist of material from underground to the first batch of concentrate shipped. To minimize the time it would take to produce concentrate without stopping because of a lack of feed material a project was undertaken to integrate the mining model with a concentrator production schedule () in the most capital-effective manner. A secondary goal was to ensure detailed stockpiling requirements, as the concentrator is in an area where ?visual pollution? is to be avoided. To achieve this a dynamic stockpile model was created utilizing the mine production schedule resolved into a daily production figure. Four different concentrator development models were then proposed. The difference between the mine production and concentrator consumption was integrated over the life of the mine to provide the accumulated stockpile tonnages for both Merensky and UG2 ores. The stockpile levels were never allowed to fall below zero to prevent a situation where the concentrator was operational without feed material,. When a development option was selected, the standard metallurgical performance calculations were used to derive a concentrate production schedule, that was then used as a basis for commercial concentrate sale negotiations.

Jan 1, 2012

By M. A. Belokrys, F. O. Milovich, D. D. Aksenova, V. A. Ignatkina, V. A. Bocharov, A. A. Kayumov

Copper remains one of the most sought-after metals in the industry. Tennantite (Cu12As4S13) and tetrahedrite (Cu12Sb4S13) that occur in pyrite copper, copper-zinc and polymetallic ores are an additional reserve for increasing technological parameters of flotation. Pyrite mass (85% and more) has similar flotation properties to other sulfide minerals, and imperfection of reagent regime is a common problem that occurs during quality copper concentrate processing. Due to tennantite's and chalcopyrite's differences in flotation properties with butyl xanthate at pH > 10, tennantite often reports to the flotation tails. Hight alkalinity of the medium increases the oxidation level of sulfide minerals, thus increasing the concentration of S2O3 2-, SO3 2- SO4 2-. At processing facilities in the Russian Federation, the concentration of thiosulfate ions in pulp is in the range of 0.5 to 1.5 g/l and higher, which leads to a decrease in flotation activity of the tennantite. The effect of butyl xanthate (as standard), thionocarbamate, dithiophosphate and M-TF (a mixture of dithiophosphate and thionocarbamate) on monomineral (tennantite and pyrite) flotation in the presence of sodium thiosulfate was studied. The variable parameters of the "thiosulfate-collector" flotation complex were thiosulfate concentration (100-900); pH (8-12,5). The scientific methods included contact angle for hydration assessment; TEM for surface studies; UV spectroscopy and iodometric titration for solubility control. Comprehensive studies have established a connection between the concentration of thiosulfate ions and tennantite flotation selectivity. Flotation activity of tennantite is higher at pH 8 with a thiosulfate concentration under 300 mg/l. Pyrite remains active with butyl xanthate under the same conditions. TEM images of the surface films of the collectors on pyrite were acquired at pH 8. The MTF provides the biggest difference in adsorption, wettability and flotation activity between tennantite and pyrite at pH 8 and thiosulfate concentration under 300 mg/l, in comparison with butyl xanthate. The results of the research will be applied to improve selective reagent regimes of tennantite minerals flotation. Keywords: Tennantite, pyrite, chalcopyrite, sphalerite, flotation, sulfhydryl collectors, thiosulfate, adsorption, mechanism, reagent regime

Jan 1, 2020

By D. K. Weatherley, T. P. Oladele, L. B. Bbosa

Comminution is a critical stage of mineral processing which aims to reduce the size of ore particles through breakage, consequently increasing the likelihood of liberation of valuable minerals. Several factors, such as pre-existing cracks, mineralogical composition and particle size, are known to affect ore breakage behaviour. While investigating the contributing role of each factor is essential to improve understanding of breakage, isolating individual factors by experiment is typically impractical. Numerical techniques such as the Bonded Particle Model-Discrete Element Method (BPM-DEM) have been developed as a means of studying closely controlled breakage conditions. This study evaluates this technique in modelling the effect of pre-existing cracks breakage behaviour for synthetic ore specimens during impact breakage in a short impact load cell (SILC). Synthetic ore was modelled as a collection of discrete entities connected by brittle-elastic beams. Model parameters were calibrated against macroscopic material properties of a conventional homogenous synthetic ore. The extent of pre-existing cracks within specimens was prescribed by varying discontinuities between the connecting entities. An approach with the insertion of seed points was used to model the mineralogy of the specimens. Results showed that pre-existing cracks resulted in a decrease in the fracture force as the crack density increased. Additionally, the irregularity of fracture patterns within rock specimens after impact became more apparent as the crack density increased. The findings were used to emphasise some of the attributable causes of the variation observed between ore hardness characterisation tests and in situ ore behaviour. Keywords: Element Method; Bonded Particle Model, synthetic rock sample; rock fracture, preexisting cracks

Jan 1, 2020

By W. P. C. Duyvesteyn, J. R. Cutland, J. R. L. Russell

In 1970 it was decided to build a large new plant at the Chingola Division of N.C.C.M., Ltd., to treat concentrator tailings and leach residues with a low copper content by a leach-solvent extraction-electrowinning process. In order to assist in the establishment of the design parameters for the new plant, and to study the interaction of this plant with the existing leach-electrowinning plant, mathematical models, formulated as linear programs, have been developed and used extensively. The paper outlines the metallurgy of the plants and describes briefly the way in which the models have been formulated and used. The formulation involved the use of separable programming to form the products of some variables.

Jan 1, 2014

By F. Botha

South Africa is amongst the 40 driest counties in the world, with extreme weather conditions and beset by both droughts and floods. Coupled with economic growth is an increased demand on water resources and, as with all other industrial developments, mining requires large volumes of water, which is likely to have an impact on the environment. Further to this, the mining industry also realizes that minerals are a non-renewable resource and the contribution to wealth creation from mineral extraction is not everlasting. It serves as an economic boost and careful planning is required to ensure that the legacy of mining is sustainable, and that some of the returns from mining provide continual economic and social prosperity.

Jan 1, 2012

By B. Kweto, W. Legodi, C. van Buuren, R. F. Sandenbergh

Biooxidation, and especially the BIOX® process, is a viable, economical and environmentally attractive process to liberate gold hosted in refractory sulfides by oxidatively leaching the sulfides as soluble sulfates. The moderate to high cyanide consumption during the subsequent cyanidiation of the washed biooxidation residue is probably caused by the retention on the solids of labile sulfur species formed during the multi-electron oxidation process of sulfide to sulfate. In this work the nature and mode of transport of the cyanicides in the products from the mesophile BIOX® process, as well as that of the combined mesophile and thermophile bioxidation process, were considered and strategies to reduce cyanide consumption evaluated. It was found that labile sulfur species were the major cyanide consumers in the mesophile biooxidation product, forming predominantly thiocyanate during cyanidation. The transfer of labile sulfur species was only marginally decreased by more intensive and thorough washing of the biooxidation products with warm and hot water, intense stirring and warm caustic leaching. A major reduction in cyanide consumption was however achieved by using a combined mesophile and thermophile biooxidation process. Keywords: Biooxidation, refractory sulfide gold ores, cyanide consumption

Jan 1, 2020

By P. L. Crouse

"SynopsisFluorine – in the form of hydrofluoric acid, anhydrous hydrogen fluoride, elemental gaseous fluorine, fluoropolymers, volatile inorganic fluorides, and more – has played, and still plays, a major role in the nuclear industry. In order to enrich uranium, the metal has to be in the gaseous state. While more exotic methods are known, the standard and most cost-competitive way of achieving this is by means of uranium hexafluoride (UF6). This compound sublimates at low temperatures, and the vapour is enriched using centrifugal processes. The industrial preparation of uranium hexafluoride requires both elemental fluorine gas and anhydrous hydrogen fluoride (HF). HF is prepared by the reaction of sulphuric acid with fluorspar (CaF2). Fluorine gas in turn is prepared by the electrolysis of HF. Yellowcake is first converted to uranium tetrafluoride (UF4), using HF, after which the compound is treated with fluorine to yield UF6. After enrichment, the UF6 is reduced to UO2 for use in fuel elements in pellet form.South Africa has the largest reserves of fluorspar internationally, and is the third largest producer after Mexico and China. Fluorine technology has many associated difficulties, because of the reactivity of fluorine and the toxicity of HF. The main barriers to entry into the fluorochemical industry are thus the abilities to produce both HF and F2. Both these substances are produced locally, at the industrial scale, at Pelchem SOC Ltd. Should South Africa contemplate developing its own nuclear fuel cycle as part of the awaited new-build nuclear project, it will be imperative to leverage the existing skills with respect to fluorine technology, resident at both Pelchem and Necsa, for this purpose. This paper summarizes the fluorochemical skills developed locally over the past several decades, and suggests strategies for maintaining the technology base and developing it for the next generation of scientists and engineers.IntroductionFluorine chemistry has always had a very close relationship with the nuclear industry. Although the first mention of fluorspar was recorded in the sixteenth century, and the fundamentals had been well-developed by the Second World War, it was only during the Manhattan Project (Banks et al., 1994), when almost unlimited funds were made available for the large-scale industrialization of fluorine and related compounds, that the technology took off. Expertise in both the chemistry and the engineering aspects of fluorine is essential for the design and running of several of the unit processes in the nuclear fuel cycle."

Jan 1, 2015

By Ronald J. Roman

All mining and milling complexes can, within limits, operate at a variety of production rates. Factors of economic importance that are affected by production rates are costs per unit production, recovery and product grade. Once the relationship between the production rate and cost is established, dynamic programming techniques can be used to define the optimum production schedule (that is, the production schedule that maximizes the present worth of the operation) for the life of the deposit. In general, assuming that the capacity and efficiency of the physical plant remain unchanged throughout the life of the deposit, the optimum production rate is not constant for the life of the deposit, but declines gradually as the deposit is being exhausted.

Jan 1, 2014

By P. Pięta, A. Surowiak, T. Niedoba

In a flotation process of copper ore three factors were measured: copper grade in concentrate (β), copper grade in tailings (J) and recovery of copper in concentrate (e). The experiment was conducted by means of the Jameson cell. The factors influencing the quality of the process were particle size (d), time of separation (t), type of the collector (k) and dosage of the collector (s). The considered vector function was then [β(d, t, k, s), J(d, t, k, s), e(d, t, k, s)]. Optimisation achieved was based on determining the values of the adjustable factors (d, t, k, s). The goal was to obtain the highest possible values of functions β and e (maximum) and the lowest possible values of function J (minimum). To this purpose the taxonomic methods were applied. Keywords: Flotation, copper ore, lithology, flotation agents, particle size distribution, taxonomic methods

Jan 1, 2020

By R. Weideman, K. du Preez

Biological sulfate reduction has become a successful treatment alternative for acid mine drainage and Mintek is developing biological processes for treatment of highsulfate mine waters. Treatment of these high-sulfate waters is achieved by sulfatereducing bacteria that reduce sulfate to produce sulfide as a product, in the form of H2S and HS− at neutral pH. This introduces the opportunity to apply treated effluents from biological treatment processes for the recovery of metals, such as copper, from metallurgical waste streams. This study models the kinetics of copper sulfide precipitation from a complex bioleach liquor. The results indicated a rapid rate of reaction and the formation of covellite, suggesting the potential to use biogenic sulfide to recover copper as a metal sulfide product.

Jan 1, 2023

By T. Ono, B. Altansukh, S. Kawamura, K. Haga, A. Shibayama, Y. Takasaki

In recent years, the grade of silica in zinc concentrate has increased due to the degradation of zinc content and the increase in impurity content in natural ores. It implies that the development of silica removal technology from zinc concentrate is necessary to solve problems in the smelting process caused by the high content of silica in zinc concentrate. In this paper, the authors investigated the silica removal processes from silica-rich zinc concentrate by mineral processing approaches such as re-grinding and flotation. This study focused on the pulverisation process as a pretreatment for the investigation of individual minerals' liberation from the silica-rich zinc concentrates using different kinds of pulverisers. Flotation experiments were performed to separate silica and zinc concentrate from the pulverizsd feed sample using a pH regulator (NaOH), activator (CuSO4), collecting agent (PAX), and foaming agent (DOW froth 250). Results showed that the liberation rate of silica (SiO2) was reached 75% from 13% by pulverisation in an attritor with a 2 mm ball in diameter, while silica accumulated in a fraction over 20 mm in size. Flotation experiments indicated that silica removal efficiency was achieved by 44% from + 20 mm fraction obtained from pulverisation whereas the grade of silica in froth reached 1.85 mass% from 4.5 mass%. Results indicate that silica could selectively separate from silica-rich zinc concentrate, and 99.8 % zinc recovery is achieved under the studied conditions. Keywords: Zinc concentrate, silica, pulverisation, liberation, sieving, flotation

Jan 1, 2020

By N. Morris

In South Africa, diamonds are mined predominantly in rural areas. Kimberlitic diamonds dominate in Limpopo and the Northern Cape Provinces whereas alluvial diamonds are mainly sourced from the North West and Northern Cape Provinces. There are a few large and medium sized diamond companies (De Beers, Petra Diamonds, Trans Hex, Rockwell and Alexkor). There are many smaller companies involved in diamond mining, mostly alluvial diamond mines. The nature of alluvial diamond deposits is that they are aerially more extensive and thus their surface impacts are more pervasive: The recent downturn in diamond prices has resulted in the sudden cessation of mining at many small and medium diamond operations. The South African Mining Charter requires all mines, including diamond mines, to subscribe' to .the following empowerment objectives:

Jan 1, 2010

By S. G. Mgenge, J. D. Steenkamp

Tronox Namakwa Sands operates two ilmenite smelters for the production of high-titania slag and low-manganese pig iron. Slag or metal is tapped from one of two product-specific, bi-level tap-holes. In this paper the refractory design specific to the tap-hole refractory layout is described, as well as practices for slag and metal tapping and refractory maintenance. Further developments planned are briefly described.

Jan 1, 2014

By E. van Steen, G. M. Leteba

Optimizing the catalytic performance of multimetallic nanoparticle (NP) catalysts demands a concrete understanding of their design, while preferentially deploying wet chemical synthesis procedures to precisely control surface structural properties. Here we report the influence of reductants such as hydrogen-rich tetrabutylammonium borohydride (TBAB) and carbon monoxide-rich molybdenum carbonyl (Mo(CO)6) on the shape and morphological evolution of Pt-based binary (PtNi and PtCo) and ternary (PtNiAu and PtCoAu) nanostructures derived from a homogeneous solution of aminebased surface active agents (surfactants) in a high boiling point solvent. We successfully synthesized nanostructures exhibiting well-defined and composition-controlled surfaces deploying a one-pot synthetic approach. The development of the surface properties was, however, observed to be alloyspecific. The resultant highly monodisperse alloy NP with narrow size distributions and facet-oriented surfaces are expected to display enhanced functionality as catalysts for utilization in specific chemical reactions.

Jun 1, 2021

By S. Mohanty, K. Sarangi, S. Dash, P. P. Patra

Industrial effluent from various industries contains heavy metals that are a serious threat to humans, flora and fauna in water bodies, and the environment. The heavy metals are dumped after precipitation, which has serious environmental consequences. In this paper, a 2D axi-symmetry CFD model has been developed to study the extraction of chromium ion from industrial effluent, in a hollow fibre membrane, using Alamine 336 as the carrier and kerosene as the diluent. The Navier Stokes equation was used to predict the velocity profile of the aqueous and organic phases, and species transport equation, which considers both convective and diffusive mass transfer, was used to predict the concentration profile of the chromium ion in the computational domain. The distribution coefficient was experimentally determined at a pH 4, which was found to be the optimum pH. Numerical simulations were performed considering 11.11 mol/m3 of initial feed concentration for chromium ions and extractant concentration of 0.2 M. Simulations were carried out with various aqueous and organic flow rates, and validated with experimental data. Keywords: CFD, metal extraction, hollow fibre membrane, heavy metals

Jan 1, 2020

By V. E. Cogho

Optimum Coal Mine comprises numerous defunct, active, and future mining sections. The mine is primarily a large opencast coal mine; however, underground mining activities will be increasing steadily over the next five years. Opencast and underground mining activities have a significant impact on surface and groundwater resources. To ensure that the mine will be able to continue with its mining operations in the catchment, the extent of this impact requires that substantial intervention and mitigation measures need to be implemented to ensure the environmental integrity and economic use of the catchment's water resources. In developing a sustainable long-term mine water management strategy, numerous scenarios had to be analysed. The various scenarios are a combination of water and land management activities. The main components of the mine's integrated water management strategy include: ? Management of water recharge by continual and appropriate rehabilitation of disturbed land ? Beneficial re-use of impacted mine water for coal plant process water and mining operations ? Reclamation and desalination of remaining excess impacted mine water to potable standard. From the mine's long-term water balance, it is evident that the continued implementation of numerous water management actions is required to mitigate the water resources impact in a sustainable manner. In addition, the installation of a water reclamation plant at Optimum Coal Mine (15Ml/day) is a key step for the mine to achieve a zero impact target.

Jan 1, 2012

By S. Ramatsoma, D. N. C. Phillpotts, B. Whitehead

Changes in flotation performance have been correlated to changes in froth structure, velocity and stability. Literature has shown that when the aeration rate is varied for a specific float cell, the recovery of the valuable mineral reaches a peak which also coincides with a peak in the air recovery – a measure of froth stability. Peak air recovery optimisation methodology is a way to use direct readings of physical phenomena by froth cameras to optimise the metallurgical performance of a flotation plant. The aim of this paper is to show the transient nature of the peak air recovery value and the variety of conditions required to attain the peak air recovery on an industrial flotation plant with tight base-layer control of the feed and internal conditions. Industrial site tests that were conducted under controlled conditions showed different peak values at significantly different corresponding aeration rates during normal operation. The measured peak air recovery points corresponded to maximum PGM recovery during normal flotation, as expected. This dynamic nature of the peak air recovery point conditions has not previously been discussed in literature and indicates the need for online measuring equipment and informs the design of process control algorithms required to exploit the phenomenon for optimisation. Keywords: Froth flotation, flotation control, flotation optimisation, peak air recovery

Jan 1, 2020

By J. Petersen, H. Naderi, H. Zare, M. H. Nikzad, M. Karimi

In the copper electrorefining process, the dissolution of anodes is significantly reduced or even stopped when the passivation phenomenon occurs. The results of this phenomenon are increasing energy consumption, residual formatting, and voltage levels in the cell. In this study, the electrochemical behaviour of blister copper in the presence of sodium persulfate (PDS) was studied. The electrochemical methods of LPR, Tafel, and Electrochemical Impedance Spectroscopy (EIS) were used. The results showed that the addition of sodium persulfate activates the electrode surface and increases the open circuit potential. In the presence of PDS, the polarisation resistance of the electrode shows an increasing or decreasing tendency, based on the PDS concentration. This tendency is probably due to the formation of surface layers (such as slime layer or copper sulfate) and dissolution of this layer at various concentrations of PDS. The lowest polarisation resistance of 1.8 ohms and the highest corrosion current of 60.6×10-3 and 36.6×10-3 A/cm2 from LPR and Tafel techniques respectively were obtained at the concentration of 40 g/l PDS. Based on the results of potentiodynamic and electrochemical impedance spectroscopy tests, the addition of sodium persulfate to the solution reduces the corrosion resistance, therefore the passivation time of the blister copper anode increases. Keywords: Blister copper, electrorefining, sodium persulfate, anodic passivation

Jan 1, 2020